Top-opening carton having an unique end flap arrangement

ABSTRACT

A top-opening, rectangular paperboard carton including top, bottom, front wall, rear wall, and end walls, together defining an enclosure and provided with an unique end flap arrangement which facilitates opening and reclosure of the carton.

nited States Patent [191 uttery et al. I

[ TOP-OPENING CARTON HAVING AN UNIQUE END FLAP ARRANGEMENT [75] Inventors: Kenneth T. Butteryt Richard G. Haas, both of Parchment, Mich.

[73] Assignee: Brown Company, Kalamazoo, Mich.

[22] Filed: Jan. 3, 1972 [21] Appl. No.: 214,707

Related U.S. Application Data [63] Continuation-impart of Ser. No. 139,657, May 3,

1971, Pat. No. 3,734,390.

[52] U.S. Cl. 229/36, 229/51 TS, 229/51 TC [51] Int. Cl 365d 5/22 [58] Field of Search 229/51 TS, 51 TC, 51 SC,

[56] References Cited UNITED STATES PATENTS 3,059,827 10/1962 Pellaton et al... 229/51 TC X 3,111,255 11/1963 Skowronski 229/51 TS 3,128,934 4/1964 Jacke 229/51 TC X 3,438,566 4/1969 Mahon 229/51 TC 3,462,066 8/1969 Farquhar... 229/5] TS X 3,396,898 3/1968 Dorfmann... 229/36 3,361,327 1/1968 Waldrop 229/51 TC X Primary Examiner-George E. Lowrance Assistant Examiner-Stephen P. Garbe Attorney, Agent, or Firm-Gordon W, Hueschen [57] ABSCT A top-opening, rectangular paperboard carton including top, bottom, front wall, rear wall, and end walls, together defining an enclosure and provided with an unique end flap arrangement which facilitates opening and reclosure of the carton.

10 Claims, 3 Drawing Figures PAIENIEUMAR 19 m4 FIES TOP-OPENING CARTON HAVING AN UNIQUE END FLAP ARRANGEMENT CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation-impart of copending application U.S. Ser. No. 139,657, now U.S. Pat. No. 3,734,390, filed on May 3, 1971.

BACKGROUND OF THE INVENTION This invention relates to cartons, and more particularly, to improved cartons for packaging foodstuffs such as ice cream.

Paperboard cartons are a widely-accepted means for packaging various materials including foodstuffs. Such cartons usually are erected and filled with the normal access opening or cover means in a sealed condition. Typical such cartons are shown in U.S. Pat. Nos. 3,361,328 and 3,410,476.

While it is desirable for aesthetical and space-saving reasons to have a carton having a flat, square end, with the heretofore known reclosable paperboard cartons the cover or top panel and flaps still project outwardly to a greater or lesser extent once the carton is opened and then reclosed.

The carton design of the present invention obviates the foregoing drawback and provides several advantages with an unique end flap arrangement which facilitates the opening and'reclosure of the carton. In addition, the present invention facilitates the erection of a carton on certain types of automatic equipment because additional area for the placement of vacuum suction cups for manipulating the carton is made available.

Thus it is an object of the present invention to provide a carton for the packaging of foodstuffs which has an unique end flap arrangement and which can be readily handled on automatic equipment.

Still other objects will readily present themselves to one skilled in the art upon reference to the ensuing specification, the drawings, and the claims.

SUMMARY OF THE INVENTION The carton of the present invention can be defined as a top-opening carton having a bottom panel; a front wall hingedly connected to one edge of the bottom panel; a rear wall hingedly connected along one edge thereof to the opposite edge of the bottom panel; a top panel hingedly connected to the opposite edge of the rear panel; a front panel hingedly connected to the top panel and overlapping the front wall; bottom panel end flaps hingedly connected to the bottom panel and constituting one layer of carton end walls; top panel end flaps hingedly connected to the top panel, provided with an extension at the edge thereof opposite the hinged connection. and overlapping the bottom panel end flaps at each end; rear wall end flaps and front wall end flaps hingedly connected to rear wall and front wall, respectively, provided with a tear-out section in each flap adhesively affixed to a top panel end flap, and overlapping the bottom panel end flaps and the top panel end flaps. The front wall end flaps are also provided with a cut-out or an opening in the main section thereof adjacent to the tear-out section and situated below the extension of the underlying top panel end flap. Preferably a pull-up tab is provided in the tear-out section of the front wall end flaps.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a plan view of an integral carton blank cut and scored so as to provide a carton of the present invention;

FIG. 2 is a top perspective view showing a sealed carton erected from the blank of FIG. 1; and

FIG. 3 is a top perspective view showing an opened carton erected from the blank of FIG. 1.

DESCRIPTION OF THE PREFERRED EMBODIMENTS In the accompanying drawings all parts are numbered and the same numbers are used to identify the same parts in the several FIGURES. Additionally, areas having an adhesive applied thereon are indicated by stippled shading.

Referring to FIG. 1, carton blank comprises bottom panel 11, and front wall 12 and rear wall 13 both hingedly connected to bottom panel 11. Top panel 14 is hingedly connected to rear wall 13, and front panel 15 is hingedly connected to top panel 14 and adapted to overlap front wall 12 when the carton is erected.

Bottom panel 11 is provided with bottom panel end flaps 16 and 17 hingedly connected thereto which constitute one layer of end walls for the erected carton. Similarly front wall 12 is provided with front wall end flaps 18 and 19 hingedly connected thereto and adapted to overlap bottom panel end flaps 16 and 17, respectively, when the carton is erected. By the same token, rear wall 13 is provided with rear end flaps 20 and 21 hingedly connected thereto and also adapted to overlap bottom panel end flaps 16 and 17, respectively, when the carton is erected.

Top panel 14 is provided with top panel end flaps 22 and 23 which are hingedly connected thereto and which overlap bottom panel end flaps l6 and 17, respectively. Front wall end flaps 18 and 19 and rear wall end flaps 20 and 21 overlap top panel end flaps 22 and Detachable carton opening means is provided in front panel 15 and comprises lift tab 24 and adhesive region 25 which are adapted for adhesive affixation to cut scored regions 27 and 28 in front wall 12. In lieu thereof a peel strip having an adhesive region thereon can also be used, if desired. Reclosure tab 29 is provided in front panel 15. Reclosure slot 30 in front wall 12 is adapted to receive tab 29.

The end flap arrangement shown in the FIGURES is the essential feature of the present invention. This particular arrangement provides an effective end closure for the carton having a flat, square appearance yet a closure which permits an easy opening of the carton. As shown in FIG. 1, front wall end flaps 18 and 19 comprise main sections 32 and 33 and tear-out sections 34 and 35, respectively, as well as respective openings 36 and 37 in main sections 32 and 33 situated adjacent to tear-out section 34 and and spaced from the edges of the front wall end flaps 18 and 19. Preferably, score lines 38 and 39 traverse both the main sections and the tear-out sections of front wall end flaps l8 and 19 and define pull-up tabs 40 and 41 which are contiguous to openings 37 and 37 in main sections 32 and 33.

Similarly, rear wall end flaps 20 and 21 comprise main sections 42 and 43 and tear-out sections 44 and 45, respectively. Score line 46 in rear wall end flap 20 is aligned with score line 38 in front wall end flap l8,

and score line 47 in rear wall end flap 21 is aligned with score line 39 in front wall end flap 19 when a carton is erected from blank 10.

Main sections 32 and 42 are adapted to adhesive affixation to bottom panel end flap 16 and main sections 33 and 43 are adapted for adhesive affixation to bottom panel end flap l7. Inasmuch as top panel end flaps 22 and 23 also overlap end flaps 16 and 17, respectively, tear-out sections 34 and 44 are adapted for adhesive affixation to end flap 22 and tear-out sections 35 and are adapted to adhesive affixation to end flap 23.

Tear-out sections 34, 35, 44 and 45 of the end flaps are delineated from the respective main sections 32, 33, 42 and 43 by severance lines 48, 49, 50, 51, 52 and 53. It should be noted that lines and 51 preferably do not extend all the way to the respective outer corners of front wall end flaps 18 and 19. This arrangement provides a tight. substantially leak-proof carton corner, and when an erected carton is opened the relatively small unperforated area will tear to the corner in any event without difficulty. When an erected and glued carton is subsequently opened, these lines are severed and tear-out sections 34, 35, 44 and 45 remain permanently attached to the respective top panel end flaps 22 and 23. A pocket suitable for the insertion of top panel end flap 22 upon carton reclosure is formed through cooperation of portions 62 and 54 delineated in main sections 32 and 42 by respective score lines such as crease scores 38 and 46. Similarly, a pocket for top panel end flap 23 is formed by cooperating portions 63 and delineated by score lines such as crease scores 39 and 47 in respective main sections 33 and 43. Portions 62, 63, 54 and 55 may be embossed, if desired, so as to form a somewhat larger pocket. The removal and insertion of flaps 22 and 23 in the aforementioned pockets can be further facilitated, if desired, by providing crease scores, lines of weakening, or the like, at the outer corners thereof. Lines of weakening such as perforated lines 56, 57, 58 and 59 are preferred. Lines 56 and 58 in flap 22 define protruding portions 64 and 66 and lines 57 and 59 define protruding portions 65 and 67.

Top panel end flaps 22 and 23 are also provided with extensions 60 and 61 at the ends thereof opposite those hingedly connected to top panel 14. The configuration of tear-out sections 34, 44 and 35, 45 is such that portions thereof overlap also extensions 60 and 61 and are adhesively attached thereto. Extensions 60 and 61 in this manner provide reinforcement for said tear-out sections. This arrangement also facilitates the initial opening of a sealed carton when lines 48, 49, 50, 51, 52 and 53 have to be severed.

By designing a top panel end flap such as flap 22 in the foregoing manner several advantages are obtained. Extension 60 provides a central region in flap 22 which is as wide as practicable from the standpoint of economical paperboard utilization in carton blank layout for printing and cutting. A relatively wide central region in flap 22 is desirable because any of the container contents that may be squeezed out over bottom panel end flap 16 as a result of container overfill with spread out between flap l6 and flap 22, and a wide central region will permit retention of the squeezed-out contents between these flaps. In addition, tear-out sections 34 and 44 are reinforced.

Protruding portions 64 and 66 project beyond respective tear-out sections 44 and 34, and perforated lines 56 and 58 permit portions 64 and 66 to easily slide in and out of said top panel end flap pockets upon opening and reclosing of an erected carton with a minimum of sliding friction. The configuration of protruding portions 64 and 66 also permits adhesive sealing of the carton and relatively close to top panel 11.

Upon assembly of a carton from blank 10 shown in FIG. 1, blank 10 is first folded so that front wall 12 lines onto bottom panel 11 and cut scored regions 27 and 28 are exposed. Then top panel 14 and front panel 15 are folded over so that adhesive regions 25 and 26 are superimposed over cut scored regions 28 and 29 and are adhesively attached thereto. The result is a folded tube which can be waxed or otherwise suitably treated at this stage of construction.

To erect a carton so constructed for filling, the folded tube-like blank is squared up on a conventional squaring machine or the like, and one end of the carton closed by first folding bottom panel end flap such as flap 16. Top panel end flap 22 is then folded over flap 16, and subsequently front wall and rear wall end flaps l8 and 20, respectively, folded thereover.

lf heat-activatable adhesive is applied on the indicated adhesive regions, affixation of the several flaps is accomplished by heating these regions and then suitably pressing down the flaps.

A particular advantage is derived from the present arrangement of flaps in this regard because heat has to be applied only to the outermost set of end flaps whereby the possibility ofa foodstuff such as ice cream being heated or overheated is minimized. In the alternative, a hot melt adhesive may be applied on the aforesaid areas at the machine erecting the cartons so as to accomplish the same result as with a pre-applied, heat-activated adhesive. When using a hot melt adhesive, the need for heat-activating machinery is, of course, obviated.

The erected carton now can be filled through the remaining open end in the usual manner and the open end of the filled carton subsequently closed is a sequence substantially as hereinbefore described. That is, bottom panel end flap 17 is folded over the carton end opening, top panel end flap 23 is then folded over flap l7 and thereafter front wall and rear wall end flaps l9 and 21, respectively, folded thereover. Alternatively, the first-mentioned carton end may be closed and/or tacked, as with glue, but not sealed, and then both carton ends sealed simultaneously after filling.

A sealed carton is shown in FIG. 2. The sealed carton may be opened by first gripping lift tab 24 and pulling up front panel 15. Thereafter tear-out sections 34 and 44 are severed from corresponding main sections 32 and 42 along lines 48, 50 and 52 by inserting a finger through cut-out opening 36, moving pull-up tab 40 outwardly, gripping tab 40 and then pulling in an arcuate upwardly motion whereupon underlying extension 60 will also be raised upwardly and will assist in the severance.

Simultaneously the same procedure is carried out at the other end of the carton. As a final step, top panel 14 is lifted exposing the container contents. An opened carton is shown in FIG. 3.

Reclosure of the open carton can be accomplished by returning top panel 14 to its original position, tucking in protruding portions such as 64 and 66 of flap 22 into the pocket provided therefor, i.e., between portions 62 and 54 of main sections 32 and 42 on one hand and bottom panel end flap 16 on the other, and by engaging reclosure tab 29 with reclosure slot 30. Protrucling portions 64 and 66 of flap 22 can be delineated by perforated lines 56 and 58 whereupon the protruding portions of flap 22 will easily slipout of and into the pocket. Similarly, protruding portions 65 and 67 of flap 23 delineated by lines 57 and 59 perform the same function.

The foregoing embodiments of the present invention are intended as illustrative but are not to be construed as limiting. Still other variations within the spirit and scope of this invention will readily present themselves to one skilled in the art.

I claim:

1. A top-opening paperboard carton having a bottom panel;

a front wall hingedly connected to one edge of the bottom panel;

a rear wall hingedly connected along one edge thereof to the opposite edge of the bottom panel;

a top panel hingedly connected to the opposite edge of the rear wall;

a front panel hingedly connected to the top panel and overlapping the front wall;

detachable carton opening means adhesively affixing the front panel to the front wall; rear wall end flaps each hingedly connected to the rear wall and comprising a main section and a tear- ;outsection;

top panel end flaps each hingedly connected along one edge thereof to the top panel and provided with a downwardly-protruding extension at the edge thereof opposite that hingedly connected to the top panel;

front wall end flaps each hingedly connected to the front wall. comprising a main section and a tear-out section, and provided with an opening in the main section adjacent to the tear-out section;

bottom panel end flaps each hingedly connected to the bottom panel and constituting one layer of end walls for the carton;

each of said top panel end flaps overlapping a bottom panel end flap;

said front wall end flaps and rear wall end flaps overlapping the bottom panel end flaps and the top panel end flaps, and the main section thereof being adhesively attached to a bottom panel end flap and the tear-out section thereof being adhesively attached to a top panel end flap; and

said opening in the main section of the front wall end flap being situated below said extension and spaced from the edges of the front wall end flap.

2. The top-opening paperboard carton of claim 1 wherein at least one portion of the top panel end flap protrudes beyond a tear-out section of at least one of said overlapping front wall end flap or rear wall end flap and the protruding portion is received in pocket defined by one of the front wall end flap and rear wall end flap and by the bottom panel end flap.

3. The top-opening paperboard carton of claim 2 wherein a line of weakening is provided in the top panel end flap delineating the protruding portion so as to facilitate the insertion thereof in said pocket.

4. The top-opening paperboard carton of claim ll wherein the tear-out section of the front wall end flap is provided with a pull-up tab contiguous to the opening in the main section.

5. An integral paperboard blank for forming a topopening carton cut and scored to provide a bottom panel; a front wall hingedly connected to one edge of the bottom panel; a rear wall hingedly connected along one edge thereof to the opposite edge of the bottom panel;

a top panel hingedly connected to the opposite edge of the rear wall;

a front panel hingedly connected to the top panel and adapted to overlap the front wall;

detachable carton opening means in the front panel adapted for adhesive affixation of the front panel to the front wall;

bottom panel end flaps each hingedly connected to the bottom panel and adapted to constitute one layer of end walls for the carton;

rear wall end flaps each hingedly connected to the rear wall and comprising a main section and a tearout section;

top panel end flaps each hingedly connected along one edge thereof to the top panel and provided with a downwardly-protruding extension at the edge thereof opposite that hingedly connected to the top panel;

front wall end flaps each hingedly connected to the front wall, comprising a main section and a tear-out section, and provided with an opening in the main section adjacent to the tear-out section; and

said front wall end flaps and rear wall end flaps being adapted to overlap the bottom panel end flaps and the top panel end flaps, the main section thereof being adapted to adhesive affixation to a bottom panel end flap, the tear-out section thereof being adapted for adhesive affixation to a top panel end flap, and said opening in the main section of the front wall end flap being situated so that the opening is positioned below said extension when the front wall end flaps overlap the top panel end flaps and spaced from the edges of said front wall end flap.

6. The integral paperboard blank of claim 5 wherein at least one portion of the top panel end flap is adapted to protrude beyond a tear-out section of at least one of said overlapping front wall end flap or rear wall end flap and the protruding portion is adapted to be received in a pocket defined by at least one of the front wall end flap and rear wall end flap and by the bottom panel end flap.

7. The integral paperboard blank of claim 6 wherein a line of weakening is provided in the top panel end flap delineating the protruding portion so as to facilitate the removal thereof from said pocket.

8. The integral paperboard blank of claim 5 wherein the tear-out section of the front wall end flaps is provided with a pull-up tab contiguous to the opening in the main section.

9. The top-opening paperboard carton of claim 2 wherein two portions of the top panel end flap protrude one beyond a tear-out of said overlapping front wall end flap and one beyond said overlapping rear wall end flap, and wherein one protruding portion is received in a pocket defined by the front wall end flap and the bottom panel end flap, and the other received in a pocket end flap, and wherein one protruding portion is received in a pocket defined by the front wall end flap and the bottom panel end flap. and the other received in a pocket defined by the rear wall end flap and by the bottom panel end flap.

1 UNITED S'IATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,797,728 v A Dated March 19, 1974 Inventoflg) Kenneth Buttery, et a1.

It is certified that error appears in the above-identified patent and that saidLetters Patent are hereby corrected as shown below:

" PATENT READS:' APPLICATION READS:

[75] "both'of Parchment, [75] of Kalamazoo and Michigan M Parchment, Mich. respectively" Col. 2, line 31:- Page 3, line 19 "rear end flaps" -rear wall end flaps-- Col. 2, line 63: I 7 i Page 4: 37 and 37" 1 i I 1 1 --36 and 37- Col. 3, line 4: v Page 4, line 21: "adapted to" 1 -adapted for-- Col. 3, line 11: Page 4, line 27: "adapted to" 1' -adapted for-- Col. "3 line 44: I Page 5 line 22: "at the ends" 7 1 v -'at the edges-- Col 3, line 61:; Page 6, line 4: 'v'with spread" E V -will spread- Col. 4, line 6: 7 Page 6, line 14: "Carton and" -Carton end- Col. 4, line 8:,v f a Page 6, line 16: "lines" 2 v lies--,

Claim 10 E 7 v Response and Amendment. dated Col. 7, 'line 3: 7 June 1973, Claim l0, line 2: "top end" I g 3 -top panel endsign d and sealedthis 77th day of Janu r 1975;

(SEAL? Attest: H v v I B'ICCOY-ii. GIBSON JR. c; I'fiARSHALLj DANN Attesting-Of'f-i'cer v 4 Commissioner of Patents F ORM Po-1b5o (10-69) uscoMM-oc GOING-P69 US. GO VERMDQERT PRINTING OFFICE 1969 0-366-J3l 

1. A top-opening paperboard carton having a bottom panel; a front wall hingedly connected to one edge of the bottom panel; a rear wall hingedly connected along one edge thereof to the opposite edge of the bottom panel; a top panel hingedly connected to the opposite edge of the rear wall; a front panel hingedly connected to the top panel and overlapping the front wall; detachable carton opening means adhesively affixing the front panel to the front wall; rear wall end flaps each hingedly connected to the rear wall and comprising a main section and a tear-out section; top panel end flaps each hingedly connected along one edge thereof to the top panel and provided with a downwardlyprotruding extension at the edge thereof opposite that hingedly connected to the top panel; front wall end flaps each hingedly connected to the front wall, comprising a main section and a tear-out section, and provided with an opening in the main section adjacent to the tear-out section; bottom panel end flaps each hingedly connected to the bottom panel and constituting one layer of end walls for the carton; each of said top panel end flaps overlapping a bottom panel end flap; said front wall end flaps and rear wall end flaps overlapping the bottom panel end flaps and the top panel end flaps, and the main section thereof being adhesively attached to a bottom panel end flap and the tear-out section thereof being adhesively attached to a top panel end flap; and said opening in the main section of the front wall end flap being situated below said extension and spaced from the edges of the front wall end flap.
 2. The top-opening paperboard carton of claim 1 wherein at least one portion of the top panel end flap protrudes beyond a tear-out section of at least one of said overlapping front wall end flap or rear wall end flap and the protruding portion is received in pocket defined by one of the front wall end flap and rear wall end flap and by the bottom panel end flap.
 3. The top-opening paperboard carton of claim 2 wherein a line of weakening is provided in the top panel end flap delineating the protruding portion so as to facilitate the insertion thereof in said pocket.
 4. The top-opening paperboard carton of claim 1 wherein the tear-out section of the front wall end flap is provided with a pull-up tab contiguous to the opening in the main section.
 5. An integral paperboard blank for forming a top-opening carton cut and scored to provide a bottom panel; a front wall hingedly connected to one edge of the bottom panel; a rear wall hingedly connected along one edge thereof to the opposite edge of the bottom panel; a top panel hingedly connected to the opposite edge of the rear wall; a front panel hingedly connected to the top panel and adapted to overlap the front wall; detachable carton opening means in the front panel adapted for adhesive affixation of the front panel to the front wall; bottom panel end flaps each hingedly connected to the bottom panel and adapted to constitute one layer of end walls for the carton; rear wall end flaps each hingedly connected to the rear wall and comprising a main section and a tear-out section; top panel end flaps each hingedly connected along one edge thereof to the top panel and provided with a downwardly-protruding extension at the edge thereof opposite that hingedly connected to the top panel; front wall end flaps each hingedly connected to the front wall, comprising a main section and a tear-out section, and provided with an opening in the main section adjacent to the tear-out section; and said front wall end flaps and rear wall end flaps being adapted to overlap the bottom panel end flaps and the top panel end flaps, the main section thereof being adapted to adhesive affixation to a bottom panel end flap, the tear-out section thereof being adapted for adhesive affixation to a top panel end flap, and said opening in the main section of the front wall end flap being situated so that the opening is positioned below said extension when the front wall end flaps overlap the top panel end flaps and spaced from the edges of said front wall end flap.
 6. The integral paperboard blank of claim 5 wherein at least one portion of the top panel end flap is adapted to protrude beyond a tear-out section of at least one of said overlapping front wall end flap or rear wall end flap and the protruding portion is adapted to be received in a pocket defined by at least one of the front wall end flap and rear wall end flap and by the bottom panel end flap.
 7. The integral paperboard blank of claim 6 wherein a line of weakening is provided in the top panel end flap delineating the protruding portion so as to facilitate the removal thereof from said pocket.
 8. The integral paperboard blank of claim 5 wherein the tear-out section of the front wall end flaps is provided with a pull-up tab contiguous to the opening in the main section.
 9. The top-opening paperboard carton of claim 2 wherein twO portions of the top panel end flap protrude one beyond a tear-out of said overlapping front wall end flap and one beyond said overlapping rear wall end flap, and wherein one protruding portion is received in a pocket defined by the front wall end flap and the bottom panel end flap, and the other received in a pocket defined by the rear wall end flap and by the bottom panel end flap.
 10. The integral paperboard blank of claim 6 wherein in the erected carton two portions of the top end flap protrude one beyond a tear-out section of said front wall end flap and one beyond said overlapping rear wall end flap, and wherein one protruding portion is received in a pocket defined by the front wall end flap and the bottom panel end flap, and the other received in a pocket defined by the rear wall end flap and by the bottom panel end flap. 